Method and system for remote controlling the current status of a production process of an article having a number of production process steps

ABSTRACT

A method and system for remote controlling the current status of a production process of an article having a number of production process steps; whereby a user, by means of a pickup device, communicates confirmation of completion of a production process step to a central control unit, which stores the current status of the production process of the article in a database; and the pickup device is defined by a cellular telephone, which communicates with the central control unit by sending SMS messages.

TECHNICAL FIELD

The present invention relates to a method and system for remotecontrolling the current status of the production process of an articlehaving a number of production process steps.

The present invention may be used to advantage in the metalworkingindustry for manufacturing mechanical parts, to which the followingdescription refers purely by way of example.

BACKGROUND ART

A metalworking firm manufacturing complex articles, i.e. comprisingnumerous assembled parts, does not normally produce all the partsitself, but subcontracts production, or at least part of it, of some ofthe parts to outside firms. The decision to do this depends on variousfactors. For example, the firm may not have the machinery or personnelto handle certain jobs, and purchasing the machinery or acquiringadditional personnel may prove difficult and/or economically unfeasible.

Subcontracting parts, however, may pose problems, by the firm losingdirect control of the production process of the parts subcontracted out.That is, the firm no longer has direct control over progress andscheduling of the production process of the subcontracted parts, andmust rely solely on agreements made with subcontractors.

In the past, to avoid problems caused by subcontractors failing todeliver on time, large stocks were maintained in contractors'warehouses. Given the rising cost of warehousing large stocks, however,metalworking firms currently implement a “just in time” warehousingpolicy, with stocks reduced to a bare minimum. Firms dealing withsubcontractors are therefore currently faced with the problem of how tocontrol the production process of subcontracted parts, so as to avoid,or at least predict in time, any delay in delivery on the part of thesubcontractor.

To control the production process of subcontracted parts, one possiblesolution is for the subcontractor to be equipped with one of variouscurrently marketed computerized production process control systems.This, however, is only feasible in the case of major subcontractors withadvanced computer equipment, in that computerized production processcontrol systems are expensive, are logistically complex, and call forconnecting all the subcontractor work stations to a central datacollection system.

EP-1164450-A1 discloses a monitoring device for at least one stateparameter of an object; the monitoring device has at least one sensorfor detecting the state parameters and at least one transmitterconnected to the sensor for transmitting the state parameters orassociated information. At least one converter converts the datareceived from the sensor into graphical representations and at least onemobile radio device wirelessly connected to the transmitter has adisplay for outputting the graphical representation.

DE10147744-A1 discloses a process visualization system connected to amix of sensors and actuators by means of a field bus; the visualizationsystem has distributed computers coupled by a communication unit to aserver (connected with the Internet) via a local area network (LAN)

DE19962230-A1 discloses an industrial control system, in which devicesfor registering of reports or alarms for predefined operating conditionsare available; these predefined operating conditions are processedthrough a converter so that they can be sent via a short message servicereport or an e-mail to a predefined distribution circuit according tothe nature of the operating condition encountered. The report or alarmcan be sent on one message circuit based on lists of personnel andlocations, type of message to be sent, e.g. e-mail or SMS format and caninclude files for attachment to the message.

DISCLOSURE OF INVENTION

It is an object of the present invention to provide a method and systemof remote controlling the production process of an article, whichprovide for solving the aforementioned problems, and which at the sametime are cheap and easy to implement.

According to the present invention, there is provided a method and asystem of remote controlling the current status of the productionprocess of an article having a number of production process steps asrecited in the attached claims.

BRIEF DESCRIPTION OF THE DRAWINGS

A number of non-limiting embodiments of the present invention will bedescribed by way of example with reference to the accompanying drawings,in which:

FIG. 1 shows, schematically, a system for remote controlling theproduction process of an article in accordance with the presentinvention;

FIG. 2 shows, schematically, an article controlled by the FIG. 1 system;

FIG. 3 shows, schematically, a printed sheet forming part of the FIG. 1system;

FIG. 4 shows a schematic view in perspective of a pickup device of theFIG. 1 system;

FIG. 5 shows, schematically, a further embodiment of a system for remotecontrolling the production process of an article in accordance with thepresent invention.

BEST MODE FOR CARRYING OUT THE INVENTION

Number 1 in FIG. 1 indicates as a whole a system for remote controllingthe production process of a mechanical part 2. More specifically,mechanical part 2 is subtracted by a metalworking firm 3 to asubcontractor 4, so that subcontractor 4 produces part 2 on behalf offirm 3. The production process of part 2 comprises a series of stepswhich must be performed successively by an operator of subcontractor 4.

System 1 comprises a pickup device 5, which receives confirmation ofcompletion of a production process step from a user; and a centralcontrol unit 6 connected to pickup device 5 and for storing the currentstatus of the production process of part 2 in a database 7. Database 7is of substantially known type, and comprises a series of records (notshown in detail), each of which relates to, and contains the history of,a respective part 2. Pickup device 5 and part 2 are obviously locatedphysically at the plant of subcontractor 4 producing part 2, whereascontrol unit 6 is physically located at firm 3.

Pickup device 5 comprises a mobile telephone communication device 8,which communicates with central control unit 6 by sending SMS messages9. More specifically, pickup device 5 codes confirmation of completionof a step in the production process of part 2 into an alphanumeric code10, inserts code 10 into an SMS message 9, and sends the SMS message 9to central control unit 6 over a mobile telephone network 11.

Code 10 preferably contains a sequence 12 identifying the completedproduction process step, and a sequence 13 identifying part 2. Onreceiving an SMS message 9 from pickup device 5, control unit 6 istherefore able to identify the part 2 in question, and the relativeproduction process step that has been completed. Since subcontractor 4,in fact, actually produces a lot of parts 2 of the same type or a numberof lots of parts 2 of different types simultaneously, control unit 6must be able to identify not only the production process step that hasbeen completed, but also the part 2 in question, or at least the lot towhich part 2 refers.

In a preferred embodiment shown in more detail in FIG. 4, pickup device5 is defined by a cellular telephone 8 equipped with a bar code readingdevice 14. Reading device 14 is detachable from cellular telephone 8,and comprises a communication port 15 which fits inside a similarcommunication port 16 of cellular telephone 8 when bar code readingdevice 14 is connected to cellular telephone 8. Reading device 14 mayhave and be controlled by a number of buttons 17, or may have no buttonsand be controlled using the keys on cellular telephone 8.

As shown in FIGS. 2 and 3, sequence 13 is communicated to pickup device5 by pickup device 5 reading a relative bar code 18 printed on a label19 associated with part 2. Label 19 may be attached directly to part 2,as shown in FIG. 2, or may be attached to a production card (not shown)of part 2, or to a drawing of part 2.

Sequence 12 is communicated to pickup device 5 by pickup device 5reading a relative bar code 20. Preferably, a sheet 21 is provided, onwhich is printed a series of bar codes 20, each relating to a givenproduction process step. Next to each bar code 20 printed on sheet 21, adescription 22 of the corresponding production process step ispreferably also printed, and comprises verbal and/or pictorialinformation. Sheet 21 may also contain a drawing or the production cycleof part 2.

As shown in FIG. 1, central control unit 6 comprises an interfacecomputer 23 having a mobile telephone communication device 24; and amain computer 25 in which database 7 is stored. Communication device 24is preferably defined by a mobile telephone communication card insertedinside interface computer 23. Whereas interface computer 23 servessolely for communicating with pickup devices 5, main computer 25 mayalso be used for processing information concerning production orassembly processes carried out directly by firm 3. In other words,database 7 may contain not only records relative to parts 2 beingproduced by subcontractor 4, but also records relative to all the parts2 produced internally by firm 3 or by subcontractors 4. Data relating toparts 2 produced within firm 3 is obviously communicated to maincomputer 25 by data acquisition devices 26 connected to main computer 25over the firm's communication network.

On receiving an SMS message 9 containing a respective code 10 frompickup device 5, control unit 6 may send pickup device 5 a further SMSmessage confirming reception. In which case, pickup device 5 onlyeliminates an SMS message 9 containing a respective code 10 from its ownmemory on receiving the respective further SMS message confirmingreception from control unit 6.

In actual use, on completing a step in the production process of part 2,an operator of subcontractor 4, using pickup device 5, reads bar code 18identifying part 2, and then reads bar code 20 identifying the step inthe production process of part 2. Obviously, the information in code 18could also be contained in code 20. At this point, pickup device 5 sendsan SMS message 9 containing code 10 to control unit 6; and, ondetermining correct reception of SMS message 9, control unit 6 sendspickup device 5 a further SMS message confirming reception.

On receiving an SMS message 9 containing a respective code 10, controlunit 6 identifies the completed production process step by means ofsequence 12 in code 10, identifies part 2 by means of sequence 13 incode 10, and accordingly updates database 7 by entering completion ofthe production process step in a record relative to the part 2 inquestion.

It should be pointed out that the term production process step of part 2refers to any type of operation or sequence of operations relating to apart 2. For example, a production process step may even be a dimensionalcheck or rejection of a ruined part (even as a result of a processingerror).

In an alternative embodiment shown in FIG. 5, pickup device 5 isdispensed with, and, upon completion of a production process step ofpart 2, an operator codes completion confirmation by means of arespective numeric code 10, and transmits code 10 to central controlunit 6 over a telephone 27, connected to a fixed telephone network, bykeying a given telephone number 28 associated with control unit 6.

In a first embodiment, code 10 corresponds with the telephone number 28keyed by the user. That is, on determining an incoming call to telephonenumber 28, control unit 6 is informed that a respective productionprocess step of part 2 associated with the telephone number 28 calledhas been completed. Each production process step of part 2 is assigned arespective telephone number 28, i.e. a respective code 10 correspondingwith telephone number 28, and a call made to telephone number 28 informscontrol unit 6 that the production process step of part 2 associatedwith the telephone number 28 called has been completed. It should bepointed out that, in known manner, control unit 6 can identify thetelephone number of the telephone 27 from which the call is made, and soidentify the caller.

In a second embodiment, code 10 is completely independent of thetelephone number 28 keyed by the user. That is, on keying telephonenumber 28, the user connects respective telephone 27 to control unit 6,and, once the connection is made, transmits code 10 to control unit 6 bykeying code 10 on the keyboard of telephone 27.

In a further embodiment, which is halfway between the two describedabove, a first part of code 10 corresponds with telephone number 28keyed by the user.

Code 10 preferably comprises sequence 12 identifying the relativeproduction process step, and sequence 13 identifying part 2. Morespecifically, sequence 13 is printed on a label 19 associated with part2, and sequence 12 is printed on sheet 21 together with other sequences12 relative to other production process steps.

System 1 described above allows a firm 3 complete, real-time control ofthe production process of part 2 carried out by a subcontractor 4physically distant from firm 3. Moreover, system 1 described above isextremely cheap, and calls for no particular installation work at thesubcontractor 4 plant: pickup devices 5 and sheets 21 may be supplied byfirm 3 to subcontractor 4 for as long as required to produce one lot ofparts 2, and then returned when production is completed. Logistically,production process control is run entirely by firm 3, who thus retainsfull control of the production process, with absolutely no burden beingplaced on subcontractor 4.

1. A method of remote controlling the current status of the productionprocess of an article having a number of production process steps; themethod comprising the steps of: communicating by means of a pickupdevice (5) confirmation of completion of a production process step to acentral control unit (6) having a database (7); and storing the currentstatus of the production process of the article (2) in the database (7);the method is characterized in comprising the steps of: reading at firstcode (20) using the pickup device (5) to store in the pickup device (5)a first sequence (12) identifying the production process step; reading asecond code (18) using the pickup device (5) to store in the pickupdevice (5) a second sequence (13) identifying the article (2); codingconfirmation of completion in an alphanumeric code (10) inside thepickup device (5) by combining the first sequence (12) and the secondsequence (13); inserting the code (10) into an SMS message (9) insidethe pickup device (5); and sending the SMS message (9) to the centralcontrol unit (6) over a mobile telephone network (11) by using thepickup device (5).
 2. A method as claimed in claim 1, wherein the firstcode (20) is a bar code printed on a sheet (21) together with furtherfirst bar codes (20) relative to other production process steps.
 3. Amethod as claimed in claim 2, wherein a description (22) of the relativeproduction process step is printed an the sheet (21), close to the firstbar code (20).
 4. A method as claimed in claim 3, wherein thedescription (22) comprises verbal and/or pictorial information.
 5. Amethod as claimed in claim 1, wherein the second code (18) is a bar codeprinted on a label (19) associated with the Article (2).
 6. A method asclaimed in claim 1, wherein, on receiving the SMS message (9) containingthe code (10) from the pickup device (5), the central control unit (6)sends the pickup device (5) a further SMS message confirming reception.7. A method as claimed in claim 6, wherein the pickup device (5) onlyeliminates the SMS message (9) containing the code (10) from its memoryupon receiving from the central control unit (6) the respective furtherSMS message-confirming reception.
 8. A system for remote controlling theproduction process of an article; the system (1) comprising: a pickupdevice (5) for receiving confirmation of completion of a productionprocess step from an operator; and a central control unit (6) connectedto the pickup device (5) and which stores the current status of theproduction process of the article (2) in a database (7); the system ischaracterized in that the pickup device (5) comprises a first mobiletelephone communication device (8) which communicates with the centralcontrol unit (6) by sending SMS messages (9); the pickup device (5)codes confirmation of completion in an alphanumeric code (10), insertsthe code (10) into an SMS message (9), and sends the SMS message (9) tothe central control unit (6) over a mobile telephone network (11); thecode (10) comprises at first sequence (12), which identifies theproduction process step and is communicated to the pickup device (5) bythe pickup device (5) reading a relative first code (20); and the code(10) comprises a second sequence (13), which identifies the article (2)and is communicated to the pickup device (5) by the pickup device (5)reading a relative second code (18).
 9. A system as claimed in claim 8,wherein the first code (20) is a bar code printed on a sheet (21)together with farther first bar codes (20) relative to other productionprocess steps.
 10. A system as claimed in claim 9, wherein a description(22) of the relative production process step is printed on the sheet(21), close to the first bar code (20).
 11. A system as claimed in claim10, wherein the description (22) comprises verbal and/or pictorialinformation.
 12. A system as Claimed in claim 8, wherein, the secondcode (18) is a bar code printed on a label (19) associated with theArticle (2).
 13. A system as claimed in claim 8, wherein, on receivingthe SMS message (9) containing the code (10) from the pickup device (5),the central control unit (6) sends the pick up device (5) a further SMSmessage confirming reception.
 14. A system as claimed in claim 13,wherein the pickup device (5) only eliminates the SMS message (9)containing the code (10) from its memory upon receiving from the centralcontrol unit (6) the respective further SMS message confirmingreception.
 15. A system as claimed in claim 8, wherein the pickup device(5) is defined by a s cellular telephone (8) having a code readingdevice (14).
 16. A system as claimed in claim 15, wherein the codereading device (14) is detachable from the cellular telephone (8), andhas a first communication port (15) which fits in a second communicationport (16) on the cellular telephone (8) when the code reading device(14) is fitted to the cellular telephone (8).
 17. A system as claimed inclaim 8, wherein the central control unit (6) comprises an interfacecomputer (23) having a second mobile telephone is communication device(24); and a main computer (25) in which the database (7) is stored.